Card and process for producing the same

ABSTRACT

A process for producing a card comprising: 
     recording variable data comprising photographic data on at least one selected from a surface of a center core to be used for the card, and a back surface of an oversheet in a sheet form supplied from a roll thereof, by variable data recording means comprising a sublimation type thermal transfer device which uses a thermal transfer sheet having a dye layer imparted with a releasability, 
     superposing the center core and the oversheet to form an integral laminate; 
     cutting the integral laminate into a card form having a predetermined size. 
     The present invention also provides a process for producing a card comprising: 
     recording variable data comprising photographic data on at least a surface of a center core to be used for the card by variable data recording means comprising a sublimation type thermal transfer device which uses a thermal transfer sheet having an image-receiving layer; 
     superposing the center core and an oversheet in a sheet form supplied form a roll thereof to form an integral laminate; and 
     cutting the integral laminate into a card form having a predetermined size. 
     According to the present invention, the recording of variable data including photographic data may be automated and simplified, thereby to improve the productivity. Further, the thus produced card according to the present invention is excellent in durability since the recorded surface thereof is covered with an oversheet.

This is a continuation of application Ser. No. 07/655,117 filed on Feb.14, 1991, now abandoned.

FIELD OF THE INVENTION AND RELATED ART

The present invention relates to a card such as an ID card, a creditcard and a cash card, and to a process for producing said cards.

Hitherto, there have been known various cards such as magnetic card, ICcard, and optical card which comprise a center core comprising a resinsuch as vinyl chloride, and an oversheet disposed on the surface thereofcomprising a transparent resin sheet.

These cards are generally produced in the following manner.

First, a center core comprising a white resin plate having a thicknessof about 0.5 mm is provided and (or common) data, pattern, etc.,required for such a card are printed on the surface thereof by offsetprinting, screen printing, etc. Then, oversheets comprising thintransparent resin sheets are temporarily bonded to both surfaces of thecenter core, the entirety of the resultant laminate is subjected to hotpressing to be converted into an integral-type laminate, and cut orpunched into a card form having a predetermined size. Thereafter,letters, marks, etc. required for individual cards are provided to theresultant cards by embossing by means of an embossing encoder, and/orsuch letters and marks are written on a magnetic stripe, whereby productcards are obtained.

Recently, photographs such as facial photograph have been bonded to thecard of this type in some cases. In such a case, a photograph is bondedto a predetermined portions of the printed center core having a facialphotograph size with hands of operator, and then an oversheet islaminated on the resultant product.

As the cards having a facial photograph, (Japanese Laid-Open PatentApplication (JP-A, KOKAI) No. 120696/1988) Japanese Laid-Open PatentApplication No. 293383/1989 has proposed a card having a transparentsheet bonded to the surface thereof wherein data such as facialphotograph is recorded in the transparent sheet in advance; JapaneseLaid-Open Patent Application No. 220395/1987 has proposed a card havingan image-receiving layer formed thereon wherein data such as facialphotograph is recorded by thermal transfer recording; Japanese Laid-OpenPatent Application No. 22693/1988 has proposed a card having animage-receiving layer formed thereon wherein data such as facialphotograph is recorded by sublimation transfer recording, and thereafteran oversheet is bonded to the image-receiving layer; etc.

However, in the production method disclosed in Japanese Laid-Open PatentApplication No. 120696/1988, since manual operation for bonding thephotograph is required, the resultant productivity is low and an errorin the bonding of the photograph is liable to occur.

In the card disclosed in the Japanese Laid-Open Patent Application Nos.293383/1989 and 220395/1987, there occurs a problem in the durability ofthe data such as the facial photograph recorded in the surface of thecard or transparent sheet.

Further, in the card disclosed in Japanese Laid-Open Patent ApplicationNo. 22693/1988, a step of forming the image-receiving sheet on thesurface of the card is newly required and therefore the resultantproduction cost is increased.

SUMMARY OF THE INVENTION

A principal object of the present invention is, in view of theabove-mentioned problems encountered in the prior art, to a process forproducing a card which is capable of producing a card havingphotographic data, etc., recorded thereon without manual operation suchas bonding of a photograph while attaining a high productivity.

Another object of the present invention is to provide a card whichsurely retains photographic data, etc., and is excellent in durability.

As a result of our investigations for solving the above-mentionedproblems, we have found that photographic data may be recorded in acenter core or an oversheet constituting a card by a variable datarecording means such as thermal transfer-type printer which is capableof recording variable data including photographic data, whereby we havereached the present invention.

According to a first aspect of the present invention, there is provideda process for producing a card comprising:

recording variable data comprising photographic data on at least oneselected from a surface of a center core to be used for the card, and aback surface of an oversheet in a sheet from supplied from a rollthereof, by variable data recording means comprising a sublimation typethermal transfer device which uses a thermal transfer sheet having a dyelayer imparted with a releasability;

superposing the center core and the oversheet to form an integrallaminate; and

cutting the integral laminate into a card form having a predeterminedsize.

According to a second aspect of the present invention, there is provideda process for producing a card comprising:

recording variable data comprising photographic data on at least asurface of a center core to be used for the card by variable datarecording means comprising a sublimation type thermal transfer devicewhich uses a thermal transfer sheet having an image-receiving layer;

superposing the center core and an oversheet in a sheet from suppliedfrom a roll thereof to form an integral laminate; and

cutting the integral laminate into a card form having a predeterminedsize.

According to a third aspect of the present invention, there is provideda card comprising a center core and an oversheet disposed on at leastone surface of the center core, the card having a recorded portion on atleast one selected from a surface of the center core and a back surfaceof the oversheet; wherein the recorded portion has variable datacomprising photographic data recorded by variable data recording meanscomprising a sublimation type thermal transfer device which uses athermal transfer sheet having a dye layer imparted with a releasability.

According to a fourth aspect of the present invention, there is provideda card comprising a center core and an oversheet disposed on at leastone surface of the center core, the card having: an image-receivinglayer which has been formed on the surface of the center core by meansof a sublimation type thermal transfer device using a thermal transfermaterial having an image-receiving layer; and having a recorded portionon at least the surface of the center core; wherein the recorded portionhas variable data comprising photographic data recorded by variable datarecording means comprising the sublimation type thermal transfer deviceusing the thermal transfer sheet.

According to the present invention, the recording of variable dataincluding photographic data may be automated and simplified, thereby toimprove the productivity. Further, the thus produced card according tothe present invention is excellent in durability since the recordedsurface thereof is covered with an oversheet.

These and other objects, features and advantages of the presentinvention will become more apparent upon a consideration of thefollowing description of the preferred embodiments of the presentinvention taken in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1(A, B) is a schematic sectional view showing an embodiment of thecard according to the present invention wherein FIG. 1(A) shows a stateof recording variable data including photographic data in an oversheet;and FIG. 1(B) shows a state of a center core and an oversheet beforethese members are temporarily bonded to each other.

FIGS. 2(A, B) is a schematic sectional view showing another embodimentof the card according to the present invention wherein FIG. 2(A) shows astate of recording variable data including photographic data in anoversheet; and FIG. 2(B) shows a state of a center core and an oversheetbefore these members are temporarily bonded to each other.

FIGS. 3(A, B) is a schematic sectional view showing a still anotherembodiment of the card according to the present invention wherein FIG.3(A) shows a state of recording variable data including photographicdata in an oversheet, and FIG. 3(B) shows a state of a center core andan oversheet before these members are temporarily bonded to each other.

FIG. 4(A) is a schematic sectional view showing an embodiment of athermal transfer sheet to be used in the present invention, and FIG.4(B) is a schematic sectional view showing another embodiment of athermal transfer sheet to be used in the present invention.

FIG. 5 is a schematic view for illustrating the process for producing acard according to an embodiment of the present invention.

FIG. 6 is a block diagram for illustrating an embodiment of the variabledata recording means to be used in the process for producing a card asshown in FIG. 5.

FIGS. 7(A, B, C) is a schematic view for illustrating an embodiment ofthe method of hot-pressing a temporarily bonded laminate, wherein FIG.7(A) is a side view showing a state wherein a plurality temporarilybonded laminates are superposed; FIG. 7(B) is a perspective view showinga state wherein a plurality of temporarily bonded laminates arearranged; and FIG. 7(C) is a plan view showing a turret for effectinghot-pressing.

FIG. 8 is a schematic plan view of a magnetic card according to anembodiment of the present invention.

FIG. 9 is a schematic sectional view of the magnetic card shown in FIG.8.

FIG. 10 is a schematic view for illustrating the process for producing acard according to another embodiment of the present invention.

FIG. 11 is a schematic view for illustrating a production line forpracticing a process for producing a card according to anotherembodiment of the present invention.

FIG. 12 is a schematic view for illustrating an embodiment obtained bymodifying the embodiment shown in FIG. 11.

DESCRIPTION OF PREFERRED EMBODIMENTS

Hereinbelow, a preferred embodiment of the present invention isspecifically described with reference to accompanying drawings.

FIG. 1 is a schematic sectional view showng an embodiment of the cardaccording to the present invention wherein FIG. 1(A) shows a state ofrecording variable data including photographic data in an oversheet; andFIG. 1(B) shows a state of a center core and an oversheet before thesemembers are temporarily bonded to each other.

Referring to FIG. 1, variable data 115 including photographic data isrecorded in an oversheet 113 by a variable data recording means 102. Onthe other hand, a center core 112 has been subjected to a predeterminedprinting operation, in advance, whereby ink layers 116a and 116b areformed. Then, a card according to this embodiment is produced bytemporarily bonding an oversheet 113 and an oversheet 114 to the centercore 112 prepared above, subjecting the resultant laminate tohot-pressing, and cutting into a card form having a predetermined size.The thus produced card is one having the variable data including thephotographic data on the back side of the oversheet 113.

FIG. 2 is a schematic sectional view showing another embodiment of thecard according to the present invention wherein FIG. 2(A) shows a stateof recording variable data including photographic data in a center core;and FIG. 2(B) shows a state of a center core and an oversheet beforethese members are temporarily bonded to each other.

Referring to FIG. 2, variable data 125 including photographic data isrecorded in a predetermined region of a center core 122 other than theregion which has been subjected to a predetermined printing operation,in advance, so as to form an ink layer 126, by a variable data recordingmeans 102. Then, a card according to this embodiment is produced bytemporarily bonding an oversheet 123 and an oversheet 124 to the centercore 122 prepared above, subjecting the resultant laminate tohot-pressing, and cutting into a card form having a predetermined size.The thus produced card is one having the variable data including thephotographic data on the surface side of the center core.

In the present invention, the center core and the oversheet constitutingthe card are required to have a card adaptability and a bondingproperty. These members are also required to have a printing orlettering property in a case where they are subjected to image recordingand/or printing operation. Further, the oversheet is required to have aproperty of protecting an image against light, heat, etc. Accordingly,as the material of the center core and oversheet, one having theabove-mentioned characteristics is selected.

Such a material may be any of those known in the art which have a heatresistance and a strength to a certain extent. Specific examples thereofmay include; paper, various coated paper, polyester film, polystyrenefilm, polypropylene film, polysulfone film, aramid film, polycarbonatefilm, polyvinyl alcohol film, polyvinyl chloride film, ABS film,cellophane, etc. Among these, polyvinyl chloride film is particularlypreferred.

If the above-mentioned substrate film has a poor adhesive property withrespect to a dye layer to be formed on the surface thereof, it ispreferred to subject the substrate film to an adhesive propertyimparting treatment such as primer treatment and corona dischargetreatment. Further, it is also possible to add an ultraviolet lightabsorbing agent, and antioxidizing agent, and a heat stabilizer to theoversheet.

The oversheet may preferably have a thickness of about 0.01 to 0.2 mm,and the center core may preferably have a thickness of about 0.1 to 0.7mm. The oversheet and center core may comprise a single layer or alaminate comprising two or more layers. In a case where the center corecomprises a laminate comprising a plurality of sheets, each sheet mayhave a smaller thickness and may be provided in the form of a roll. As aresult, the card according to the present invention may constituting beproduced in such a case, as in Examples appearing hereinafter. It ispreferred to disposed the oversheet on both sides of the center core.However, it is possible to dispose the oversheet on one side of thecenter core.

When variable data including photographic data is recorded in the centercore or oversheet, such a member may be in the form of sheets, or in theform of a continuous sheet. In a case where the center core has alaminate structure, it is possible to record the variable data for thecenter core on a sheet constituting the center core before thelaminating thereof.

As the means for recording variable data including photographic data, itis possible to use one comprising a thermal transfer type printer or anink jet type printer. It is particularly preferred to use a sublimationtype thermal transfer printer, since such a printer may provide abeautiful image at a relatively low cost. The thermal transfer typeprinter may be either of a flat type or a platen type, which mayappropriately be selected depending on the form of the center core oroversheet to be recorded. Further, the thermal transfer printer may beeither of one-head type or multi-head type.

In the present invention, the contents of the recording provided by thevariable data recording means comprise at least photographic data suchas facial photograph. However, the contents of the recording may alsocomprise variable character data such as name, address, and number.Further, the variable data may also comprise data common to the cardsuch as explanation and design. When the above-mentioned various data isrecorded, all data is not necessarily recorded by using a commonprinter, but printers of differed type may be used as desired. Forexample, it is possible that the photographic data is recorded by meansof a sublimation type thermal transfer printer, and character data isrecorded by means of a melting type thermal transfer printer.

The thermal transfer sheet to be used in combination with thesublimation type thermal transfer printer may preferably be one having adye layer having a releasability. In order to impart a releasability tothe dye layer, it is possible to add to the interior of the dye layer arelease agent comprising a graft copolymer containing a releasingsegment, or to use as a binder resin for the dye layer comprising agraft copolymer containing a releasing segment.

The graft copolymer containing a releasing segment used herein may be agraft copolymer having at least one releasing segment selected from apolysiloxane segment, a fluorinated carbon segment and a long-chainalkyl segment grafted on a main chain.

As the polymer constituting the main chain, it is possible to use any ofpolymers known in the art having a reactive functional group. Preferredexamples thereof may include; cellulose type resins such as ethylcellulose, hydroxyethyl cellulose, ethyl hydroxy cellulose hydroxypropylcellulose, methyl cellulose, cellulose diacetate, cellulose triacetateand cellulose acetatebutyrate, vinyl type resins such as acrylic resin,polyvinyl alcohol, polyvinyl acetate, polyvinyl butyral, polyvinylacetal, polyvinyl acetoacetal, polyvinyl pyrrolidone, andpolyacrylamide; polyamide resin, polyurethane resin, polyester resin,etc. Among these, it is particularly preferred to use acrylic typeresin, vinyl type resin, polyester type resin, polyurethane type resin,polyamide type resin, or cellulose type resin in view of thecompatibility with the binder.

The above-mentioned releasing copolymer may be synthesized in variousmanners. Preferred examples thereof may include a method wherein a mainchain is formed, and thereafter the functional group contained in theresultant main chain is reacted with a releasing compound having afunctional group capable of reacting with that contained in the mainchain. Specific example of such a releasing copolymer may include asilicon graft copolymer synthesized in a manner wherein a siloxane mainchain containing a functional group in one end portion of the main chainis reacted with a dimethyl isocyanate, and thereafter the resultant isreacted with a polyvinyl acetoacetal containing a OH group.

In the present invention, the dye to be used for the thermal transfersheet as described above is not particularly restricted and can be anyof dyes which have been used in the conventional thermal transfer sheet.

Specific examples of such a dye may include; red dyes such as MS Red G,Macrolex Red Violet R, Ceres Red 7B, Samaron Red HBSL, and Resolin F3BS,yellow dyes such as Horon Brilliant Yellow 6GL, PTY-52, and MacrolexYellow 6G; blue dyes such as Kayaset Blue 714, Wacsorine Blue AP-FW,Horon Brilliant Blue S-R, and MS Blue 100.

Further, Waxes such as polyethylene wax, an organic filler, and aninorganic filler may be added to the dye for improving a printingproperty and a antithermalexpansion property against an image receivingsheet.

In the present invention, data common to the card such as explanationand design is not necessary be recorded by using the variable datarecording means, but such data may also be recorded in the center coreor oversheet by offset printing or screen printing.

FIG. 3 is a schematic sectional view showing another embodiment of thecard according to the present invention wherein FIG. 3(A) shows a stateof recording variable data including photographic data in a center core;and FIG. 3(B) shows a state of the center core and an oversheet beforethese members are temporarily bonded to each other.

Referring to FIG. 3, an image receiving layer 135 is formed on thecenter core 132 which has been subjected to a predetermined printingoperation, in advance, so as to form an ink layers 136a and 136b by avariable data recording means 102.

Then, variable data including photographic data is similarly recorded onthe image receiving layer 135 by the variable data recording means 102.Thereafter, a card according to this embodiment is produced bytemporarily bonding an oversheet 133 and an oversheet 134 to the centercore 132 prepared above, subjecting the resultant laminate tohot-pressing, and cutting into a card form having a predetermined size.The thus produced card is one having the variable data including thephotographic data on the surface of the center core. In such a card,since the image receiving layer is formed prior to the recording of thevariable data including photographic data, recording is effected on theink layer formed on the center core, such printing on the imagereceiving layer can be effected by using a thermal transfer sheetcomprising an image receiving layer and a dye layer as shown in FIG.4(A) by means of a sublimation type thermal transfer printer.

Referring to FIG. 4(A), a thermal transfer sheet 140 comprises asubstrate 141, a heat-resistant lubricating layer 142 formed on one sideof the substrate 141, and dye layers 143Y, 143M and 143C and an imagereceiving layer 144 formed on the other side of the substrate 141. As asubstrate film for the thermal transfer sheet 140, it is possible to useany of films known in the art having a certain property of heatresistance and strength. Specific examples thereof may include; paper,various coated paper, polyester film, polystyrene film, polypropylenefilm, polysulfone film, aramid film, polycarbonate film, etc. Amongthese, polyester film is particularly preferred.

The substrate film may preferably have a thickness of about 0.5 to 50μm, more preferably about 3 to 10 μm. It is preferred to subject thesurface of the substrate film to an adhesive property impartingtreatment.

The image receiving layer 144 comprises a resin having a dyeingproperty. Specific examples thereof may include; vinyl chloride-vinylacetate copolymer, polyester resin, epoxy resin, vinyl chloride resin,vinyl acetate resin, styrene resin, etc. Further, it is preferred to adda releasing agent to the above resin for imparting a thermal-releasingproperty to the image receiving layer 144. Specific examples of such areleasing agent may include; silicone oil, phosphate surfactant,fluorine surfactant, etc. Among these, silicone oil is particularlypreferred. Specific examples of such a silicone oil may include;modified silicone oils such as epoxy modified silicone oil, alkylmodified silicone oil, amino modified silicone oil, carboxyl modifiedsilicone oil, alcohol modified silicone oil, fluorine modified siliconeoil, alkyl-alkyl polyether modified silicone oil, epoxy polyethermodified silicone oil, polyether modified silicone oil, etc.

The above-mentioned releasing agent may be used with an amount of 0.5 to30 wt. parts per 100 wt. parts of the resin constituting the imagereceiving layer 144 so that a releasing layer is formed on the surfaceof the image receiving layer by bleeding out of the releasing agent whenthe image receiving layer is transferred. If the addition amount isbelow the above-mentioned range, a melt adhesion between the thermaltransfer sheet and the image receiving layer may occur and a printingsensitivity may be insufficient. Referring to FIG. 4(B), in order toobtain an adhesion property, a hiding property, a cushion propertybetween the image receiving layer 144 and the center core, or betweenthe ink layer and a transfer-receiving material, it is possible to forman adhesive layer 145 on the image receiving layer 144. Such an adhesivelayer 145 may be formed by using acrylic resin, nylon resin, vinylchloride-vinyl acetate copolymer, urethane resin etc.. In order toimpart a detection property, a hiding property, a cushion property, anabsorbency of an evenness of the center core, etc., it is possible toincorporate a fluorescent whitening dye, an antistatic agent, filter, apigment, a foaming agent, etc., in the image receiving layer andadhesive layer. Further, it is also possible to dispose a releasinglayer 146 between the image receiving layer 144 and the substrate 141.The releasing layer may be formed by using vinyl acetate resin,polyamide resin, polyester resin, polyurethane resin, cellulose resin,etc.

Specific example of the thermal transfer sheet 140 may comprise thesubstrate having a surface subjected to an adhesive property impartingtreatment and a heat-resistant lubricating layer 142, a multi layerformed on a predetermined region of the substrate by gravure printingcomprising a polyamide resin layer (a releasing layer 146), a vinylchloride-vinyl acetate copolymer layer (an image receiving layer 144),an acrylic resin layer (an adhesive layer 145), and dye layers 143Y,143M and 143C formed on a predetermined region of the substrate surface,respectively. In this case, an amino modified silicone oil with anamount of 5 wt. % and an epoxy modified silicone oil with an amount of 5wt. % are added to the image receiving layer, respectively.

The dye layer 143Y, 143M and 143C may be formed by using theabove-mentioned dye a resin binder, etc. A releasability is notnecessarily imparted to the dye layer 143Y, 143M or 143C. The reason forthis is that since printing is effected on the center core by the mediumof the image receiving layer 144, good printed characters can beprovided even in a case where a releasability is not imparted to the dyelayer 143Y, 143M and 143C. It is also possible to dispose a black layeron the substrate 141 in addition to the dye layers 143Y, 143M and 143Cand the image receiving layer 144.

In a case where printing is effected by using the above-mentionedintegral type thermal transfer sheet having an image receiving layerone-head type printer may be used. In a case where a multi-head typeprinter is used, it is possible to use different thermal transfermaterials respectively having an image receiving layer, a red dye layer,a yellow dye layer and a blue dye layer. Further, an alignment of aprinter in transverse direction may be either of single-line type ormulti-line type. In this case, a head of the printer has a lengthcorresponding to a number of line. Further, in multi-line, each data isindividually input to each thermal head and the thermal headindividually outputs to record the variable data.

The above-mentioned image receiving layer 135 may be formed on thecenter core 132 by using transfer operation so as to cover the entiresurface of the center core 132, or so as to cover a part thereof.

The center core and the oversheet are laminated and formed into aintegral laminate after the variable data is recorded. Such integrationmay be effected by superposing the center core and the oversheet to forma laminate, temporarily bonding these members to each other, andsubjecting the resultant laminate to hot pressing. In a case where acontinuous sheet material which has been pulled out of a roll thereof isused as the center core and oversheet, it is possible that these sheetmaterials are laminated and, temporarily bonded to each other, theresultant laminate is cut into a predetermined form having anappropriate size, and the cut product is subjected to hot pressing; orthe continuous laminate sheet without punching per se is subjected tohot pressing by using a hot roller method.

In this case, an alignment of a card in transverse direction and inlongitudinal direction may be either of single-line or multi-line.

In order to bond the center core and the oversheet to each other to forman integral laminate, it is preferred to use an appropriate bondingagent or adhesive sheet. When such an agent or sheet is used, it ispossible to reduce the hot pressing time or to lower the hot pressingtemperature. The bonding agent or adhesive sheet is required to haveproperties such that it provide a strong adhesion force, it does notaffect an image, it has an embossing adaptability, etc. Morespecifically, such an bonding agent or adhesive sheet may be onecomprising vinyl chloride-vinyl acetate type resin, nylon resin,polyester resin, etc.

Prior to the laminating and integration of the oversheet and the centercore, a predetermined member such as magnetic stripe, IC module, opticalstripe may be disposed on a predetermined position of the center core oroversheet. Further, before or after the laminating and integration ofthe center core and the oversheet, a hologram and/or a hiding layer mayalso be transferred to at least one of the above-mentioned members, asdesired.

After the center core and the oversheet are bonded to each other to forma integral laminate, the resultant laminate is punched into a card formhaving a predetermined size, and is subjected to embossing and desiredwriting by means of an embossing encoder.

According to the present invention, various cards such as magnetic card,IC card and optical card may be prepared by using the above-mentionedsteps.

Hereinbelow, the process for producing a card according to the presentinvention is described in more detail with reference to the accompanyingdrawings.

FIG. 5 is a schematic view showing a process for producing the card asshown in FIGS. 8 and 9 according to an embodiment of the presentinvention.

A magnetic card 1 shown in FIGS. 8 and 9 is one to be used for an IDcard, and therefore such a card 1 is referred to as "ID card"hereinafter.

The ID card 1 is a type of card shown in FIG. 2, and comprises alaminate of a center core comprising polyvinyl chloride as a basematerial, and oversheets 3 disposed on both sides of the center corewhich comprise a thin polyvinyl chloride sheet. The center core 2 cancomprise a single layer of a polyvinyl chloride sheet, but the centercore 2 as shown in FIG. 8 and 9 is one comprising a polyvinyl chloridesubstrate 2a and thin polyvinyl chloride sheets 2b disposed on bothsides of the substrate 2a. The center core 2 may a thickness of about0.1 to 0.7 mm, and the oversheet may have a thickness of about 0.01 to0.2 mm. In the ID card 1, variable data such as facial photograph 4,attribute data (car-code, address, name, etc.) 5 is recorded on thesurface or back surface of the center core 2. Further, an image commonto respective cards such as explanation and design is recorded on thesurface of the substrate 2a constituting the center core 2. Further, inthe ID card 1, a magnetic stripe 6 is provided, and an embossedcharacter 7 such as name and number is formed.

Next, there is described a process for producing the ID card 1 havingthe above-mentioned structure according to the present invention withthe reference to FIG. 5.

(a) Printed substrate formation step (FIG. 5, a)

First, a polyvinyl chloride sheet having a predetermined thickness isprovided an image such as explanation and design is printed on thesurface thereof by offset printing, screen printing, etc., and then theresultant printed sheet is cut or punched into a certain form having apredetermined size, whereby a printed substrate 2a is prepared.

(b) Temporary bonding step for polyvinyl chloride sheet (FIG. 5, b)

A polyvinyl chloride sheet is supplied from a roll thereof, temporarilybonded to both surfaces of the substrate 2a, and thereafter theresultant laminate is cut off.

(c) Hot pressing step (FIG. 5, c)

The laminate obtained by temporarily bonding the polyvinyl chloridesheets 2b to both surfaces of the substrate 2a is hot-pressed to bondthe polyvinyl chloride sheet 2b to the substrate 2a, whereby a centercore 2 in the form of a sheet is formed.

(d) Variable data recording step (FIG. 5, d)

Variable data such as facial photograph and attribute data is recordedon the surface of the center core by using a variable data recordingmeans.

The variable data recording means used herein comprises a printer 10, aprint output device 11, an editor 12 for editing image and character, aninput device 13 for inputting card layout data and character-code data,and a photographic data input device (CCD camera, CCD scanner, etc.) 14,as shown in FIG. 6. In the variable data recording means, when anoperator inputs variable data such as card layout data andcharacter-code data by using the input device 13, and inputs variabledata such as facial photograph by using the photographic data inputdevice 14, the image character editor 12 lays out the variable data in apredetermined position, and the print output device controls the printer10 so as to record the variable data on the surface of the center core.

The printer 10 can be a thermal transfer type, an ink-jet type, etc.,but may preferably be a sublimation type thermal transfer printer, sincesuch a printer is capable of easily providing good color images, asdescribed hereinabove.

The sublimation type thermal transfer printer for effecting imagerecording on the center core 2 may preferably be one of a flat type asshown in FIG. 6, which comprises a center core mount 16 for supportingthe center core 2 and reciprocating it with respect to a thermal head15. The thermal head 15 for effecting recording on the center core 2 maybe a one-head type as shown in FIG. 6 which has one thermal headelement. However, the thermal head 15 may also be a multi-head typecomprising a plurality of thermal head element corresponding to desiredcolors.

(e) Step for temporarily bonding oversheet and transferring magneticstripe (FIG. 5, e)

Referring to FIG. 5, an oversheet 3 supplied from a roll of polyvinylchloride sheet is temporarily bonded to both surfaces of the center coreon which variable data such as facial photograph and attribute data hasbeen recorded in the previous step, and the resultant laminate is cutoff. Further, at this time, a magnetic stripe 1a is simultaneouslytransferred to the oversheet 3 on one side.

(f) Hot pressing step (FIG. 5, f)

The temporarily bonded product 1A obtained by temporarily bonding theoversheet 3 to the center core 2 in the previous step is hot-pressed tostrongly bond the center core 2 and the oversheet 3 to each other.

Such hot pressing may be conducted in each of the following manners.

(i) Multi-step method

The temporarily bonded product 1A comprising the center core 2 and theoversheet 3 discharged from the apparatus corresponding to the previousstep is automatically superposed by the medium of caul, comprising ametal plate, etc. When a predetermined number of the products 1A aresuperposed as shown in FIG. 7(A), the entirety of the superposedproducts are hot-pressed (temperature elevation-retaining-cooling).

(ii) Parallel method

A plurality of the temporarily bonded product sheets 1A discharged fromthe apparatus corresponding to the previous step are automaticallydisposed in parallel with each other as shown in FIG. 7(B), and theentirely of the products are hot-pressed.

(iii) Sole method

In such a method, a turret as shown in FIG. 7(C) comprising a number ofpress portions 21 comprising a pair of press plates 20. The turret 22 isintermittently rotated in the direction indicated by the arrow. Whilethe pressing portion 21 passes the position P1 to P4, the turret 22receives the temporarily bonded product prepared in the previous step,and conducts heating, pressing, cooling and pressing by means of thepair of press plates 20 so as to form a laminate products 1B iscomprising the center core 2 and oversheet 3 strongly bonded to eachother. The resultant laminate product 1B is discharged to the apparatuscorresponding to the next step.

(g) Punching step (FIG. 5, g)

Referring to FIG. 5, the laminate 1B formed by hot pressing is punchedinto a card form having a predetermined size, from which unnecessarymargin portion is removed.

(h) Embossing-encoder processing step (FIG. 5, h)

The card formed in the previous step is subjected to embossing-encoderso as to form an embossing character such as name and number as shown inFIG. 8.

As a result, the ID card as shown in FIG. 8 is produced through theabove-mentioned steps.

In the present invention, in order to practice the above-mentionedprocess for producing a card, there may be used some apparatus forrespectively practicing the steps thereof. At this time, it is possibleto dispose an automatic conveying device between the respectiveapparatus so that a semi-finished product prepared in the previous stepis automatically conveyed to the apparatus corresponding to the nextstep. It is also possible to manually convey such a semi-finishedproduct.

In a case where a hologram or a hiding layer is transferred to the card,the step for transferring such a hologram or hiding layer may bepositioned before or after the step for bonding the center core and theoversheet to each other.

In the above-mentioned embodiment, the variable data such as facialphotograph is recorded on the surface of the center core. However, it isalso possible to record the variable data on back surface of the centercore of the card of the type as shown in FIG. 1, both of the surface andback surface of the center core, or the back surface of the oversheet.

When the thermal transfer material 140 as shown in FIG. 4 is used,printing may be effected on printing ink. Accordingly, the printedsubstrate 2a may be used as a center core without bonding as polyvinylchloride sheet 2b. In such a case, the step for temporarily bonding thepolyvinyl chloride sheet (FIG. 5, b) and hot pressing step (FIG. 5, c)may be omitted.

For example, referring to FIG. 10, when thermal transfer sheet 140 asshown in FIG. 4 is used, the image receiving layer 144, and dye layers143Y, 143M and 143C formed on the substrate 141 are transferred to aprinted center core 162 so as to record the variable data to the centercore 162. Thereafter, oversheets 164 supplied from rolls are temporarilybonded to both surfaces of the center core 162, resultant laminate iscut into a predetermined form having an appropriate size, and the cutproduct is subjected to hot pressing. After the center core 162 and theoversheet 164 are bonded to each other to form a integral laminate, theresultant laminate is punched into a card form having a predeterminedsize, and is subjected to embossing and desired writing by means of anembossing encoder.

In the process according to the above-mentioned embodiment, the card 1is produced from a center core 2 in the form of a sheet which has beenproduced from a substrate 2a in the form of a sheet. However, at thepresent invention is not restricted to such a process. Morespecifically, a continuous sheet supplied from a roll thereof may alsobe used as the material constituting the center core.

FIG. 11 shows such an embodiment, and schematically shows a line whereincards are continuously produced from a plurality of rolls comprisingpolyvinyl chloride sheet. In this embodiment, however, the center corecomprises a laminate of a plurality of thin sheets.

Referring to FIG. 11, reference numeral 30 denotes a roll from which atransparent polyvinyl chloride sheet 31, for an oversheet to be disposedon the card surface side is to be supplied, reference numeral 32 denotesa roll from which a transparent polyvinyl chloride sheet 33 for anoversheet to be disposed on the card back surface side is to besupplied, and reference numeral 34 denotes a roll from which atransparent polyvinyl chloride sheet 35 for a center core of the card isto be supplied. The polyvinyl chloride sheet 35 wound up in the roll 34for the center core has been provided with printed image such asexplanation and design common to all cards in advance by using an offsetprinting machine, a screen printing machine, etc., and has been coatedwith a bonding agent required for the bonding. In this figure, twopolyvinyl chloride sheets 35 are shown, but the number of such sheetsmay be increased, as desired.

Along the conveying path for the polyvinyl chloride sheet 31 for theoversheet to be disposed on the surface side of the card, there aredisposed: a surface roller 40, a sublimation type thermal transferprinter 41, a melting type thermal transfer printer 42, a magneticstrips transferring roller 43, etc. Downstream of the roller 43, thereis disposed a superposing roller.

The sublimation type thermal transfer printer 41 is one for recording acolor facial photograph and comprises three thermal heads 46a, 46b and46c respectively corresponding to yellow, magenta and cyan colors.

The melting type thermal transfer printer 42 is one for recording acharacter and a bar code, and comprises two thermal head 47a and 47brespectively corresponding to recording of these images.

Similarly as in the embodiment as shown in FIG. 2, to these printers 41and 42, there are connected: a print output device 11, an editor 12 forediting image and character, an input device 13 for inputting cardlayout data and character-code data, and a photographic data inputdevice (CCD camera, CCD scanner, etc.) 14, etc. In such a variable datarecording means, when an operator inputs variable data such as cardlayout data and character-code data by using the input device 13, andinputs variable data such as facial photograph by using the photographicdata input device 14, the image-character editor 12 lays out thevariable data in a predetermined position, the facial photograph may berecorded by means of the sublimation type thermal transfer printer, andthe character and bar code may be recorded by means of the melting typethermal transfer printer. The magnetic stripe transfer roller 43 is onefor transferring the magnetic stripe supplied from a magnetic striperoll 48 to the surface of the polyvinyl chloride sheet.

Along the conveying path for the oversheet to be disposed on the backsurface of the card, a surface roller 40 and a melting type thermaltransfer printer 49 are also disposed. The melting type thermal transferroller 49 is also controlled by the print output device 11.

Downstream of the superposing roller, there are disposed a temporarybonding hot stamper 51 for temporarily bonding the laminated sheet, aoutting device 53, a hot pressing device 55 for bonding, an automaticpunching device 57, an embossing encoder 59, etc.

The hot pressing device 55 is one shown in FIG. 7(C), wherein a numberof pressing portions comprising a pair of press plates 20 are supportedon a turret. When the turret is rotated, the pressing portion 21 passesthe positions P1 to P4 as shown in FIG. 11. Herein, the position P2 is aposition for receiving and hot-pressing the temporarily bonded product,the position P3 is a position for cooling and pressing, and the positionP4 is a position for release and discharge.

Next, there is described a process for producing a card according to theabove-mentioned production line.

A polyvinyl chloride sheet 31 for card surface is supplied from a roll30, and the surface thereof is smoothed by means of the surface roller40. On the back surface (i.e., a surface capable of contacting thecenter core) of the sheet 31, a facial photograph is continuouslyrecorded by means of a sublimation type thermal transfer printer 41. Inthis case, an alignment of a card in transverse direction may be eitherof single-line, or multi-line. A character and a bar code are recordedby means of the melting type thermal transfer printer 42, and thereaftera magnetic stripe is transferred by means of the magnetic stripetransfer roller 43.

Further, a polyvinyl chloride sheet 33 for the oversheet to be disposedon the card back surface is supplied from a roll 32, and the surfacethereof is smoothed by means of the surface roller 40. On the backsurface (i.e., a surface capable of contacting the center core) of thesheet 33, a character is recorded by means of a melting type thermaltransfer printer 49.

These polyvinyl chloride sheets 31 and 33 are respectively superposed onthe surface and back surface of the polyvinyl chloride sheet 35 suppliedfrom the roll 34 of polyvinyl chloride sheet for the center core, bymeans of the superposing roller 44, the resultant laminate is subjectedto temporary bonding by means of the hot stamper for temporary bonding,and out into a certain form having a predetermined size by means of thecutter 53. In this case, an alignment of a card in transverse directionand in longitudinal direction may be either of single-line ormulti-line. Then, the thus cut temporarily bonded product 1c is conveyedto the hot pressing device 55, and subjected to heating and pressing,and cooling and pressing by means of the pressing plates 20 to be bondedto form an integral product.

Then, the resultant product is punched into a certain form having apredetermined size, subjected to embossing encoder 59 to form anembossed character 7 as shown in FIG. 8, predetermined data is writtenin the magnetic stripe.

According to the above-mentioned production process, the ID card, asshown in FIG. 8 may be produced continuously.

In the above-mentioned production process, a plurality of sheets aretemporarily bonded to each other by means of the hot stamper 51, andthereafter the resultant laminate is cut into an appropriate size andhot-pressed. In the present invention, however, another process as shownin FIG. 12 may also be adopted. More specifically, in such a process, atemporarily bonded sheet is passed through a hot pressing device 61 tobe heated and pressed in the former stage and to be cooled and pressedin the latter stage, so that an integrated bonded product is produced.Thereafter, the resultant product is punched into a predetermined sizeby means of a punching device 63 thereby to produce a card.

Further, a hologram or hiding layer may be transferred to the cardbefore or after the embossing encoder 59, as desired.

In the embodiment as shown in FIG. 11, the variable data is recorded onthe back surface of the oversheet. However, it is also possible torecord the variable data on the surface or back surface, or both surfaceand back surface of the polyvinyl chloride sheet constituting the centercore.

As described wherein above, according to the present invention, aconventional operation for bonding a photograph may be omitted, and theprocess for producing the card may be simplified, and automated.Further, the thus produced card according to the present invention isexcellent in durability since the recorded surface thereof is coveredwith an oversheet.

Further, in an embodiment as shown in FIG. 11, wherein a plurality ofsheets are supplied from rolls, desired variable data is recordedthereon in the course, and the resultant product is laminated. Accordingto such an embodiment, the productivity for the card may be improved andthe production cost thereof may be reduced.

What is claimed is:
 1. A process for producing a cardcomprising:recording variable data comprising photographic data on atleast a surface of a card substrate to be used for the card by variabledata recording means which comprises a sublimation thermal transferdevice, while a thermal transfer sheet having an image-receiving layeris thermally transferred by the sublimation thermal transfer device ontosaid surface of said card substrate for the recording; saidimage-receiving layer of the thermal transfer sheet is disposed on saidsubstrate by the medium of a releasing layer comprising a graftcopolymer containing a releasing segment; superposing the card substrateand an oversheet in a sheet form supplied from a roll thereof to form anintegral laminate; and cutting the integral laminate into a card formhaving a predetermined size.
 2. A process according to claim 1, whereinthe card substrate comprises a continuous resin sheet.
 3. A processaccording to claim 1, wherein the card substrate comprises a continuousresin sheet obtained by superposing a plurality of resin sheets suppliedfrom rolls thereof for the formation of the card substrate.
 4. Asublimation thermal transfer system comprising:a card substrate; anoversheet to be disposed on at least one surface of said card substrate;a thermal transfer means comprising a thermal transfer sheet providedwith a dye layer imparted with a releasability by a graft copolymercontaining a releasing segment, with a releasing layer comprising agraft copolymer containing a releasing segment and with animage-receiving layer formed on the releasing layer; and animage-receiving means utilized in combination with the thermal transfermeans so as to record variable data including a photographic data as arecorded portion formed on a surface of said card substrate.